Inertial gas-liquid impactor separator with flow director

ABSTRACT

An inertial gas-liquid impactor separator includes flow director guidance structure directing and guiding flow through the housing from the inlet to the outlet along a flow path from upstream to downstream. The flow director guidance structure may include a flow controller controlling and directing flow.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. patent application Ser.No. 15/400,659, filed Jan. 6, 2017, which is a divisional of U.S. patentapplication Ser. No. 14/600,655, filed Jan. 20, 2015, now U.S. Pat. No.9,574,470, which is a divisional of U.S. patent application Ser. No.13/441,046, filed Apr. 6, 2012, now U.S. Pat. No. 8,961,641, which is adivisional of U.S. patent application Ser. No. 12/622,743, filed Nov.20, 2009, now U.S. Pat. No. 8,152,884, the contents of which areincorporated herein by reference in their entirety.

BACKGROUND AND SUMMARY

The invention relates to inertial gas-liquid impactor separators forremoving liquid particles from a gas-liquid stream, including in enginecrankcase ventilation separation applications, including closedcrankcase ventilation (CCV), and open crankcase ventilation (OCV)systems.

Inertial gas-liquid impactor separators are known in the prior art.Liquid particles are removed from a gas-liquid stream by acceleratingthe stream or aerosol to high velocities through nozzles or orifices anddirecting same against an impactor, typically causing a sharpdirectional change, effecting the noted liquid particle separation. Suchinertial impactors have various uses, including in oil separationapplications for blowby gases from the crankcase of an internalcombustion engine.

The present invention arose during continuing development efforts in theabove technology.

BRIEF DESCRIPTION OF THE DRAWINGS Prior Art

FIGS. 1-6 are taken from U.S. Pat. No. 6,290,738, incorporated herein byreference.

FIG. 1 is a schematic side sectional view of an inertial gas-liquidseparator in an engine crankcase ventilation separation application.

FIG. 2 is like FIG. 1 and shows another embodiment.

FIG. 3 is like FIG. 1 and shows another embodiment.

FIG. 4 is like FIG. 1 and shows another embodiment.

FIG. 5 is like FIG. 1 and shows another embodiment.

FIG. 6 shows a further embodiment.

Present Application

FIG. 7 is a top plan view of a flow director for an inertial gas-liquidimpactor separator in accordance with the invention.

FIG. 8 is a sectional view taken along line 8-8 of FIG. 7.

FIG. 9 is a schematic perspective view showing another embodiment of aflow director for an inertial gas-liquid impactor separator inaccordance with the invention.

FIG. 10 is like FIG. 9 and shows a further embodiment.

FIG. 11 is like FIG. 10 and shows a further embodiment.

FIG. 12 is a perspective view of another embodiment of a flow directorfor an inertial gas-liquid impactor separator in accordance with theinvention.

FIG. 13 is a top plan view of the component of FIG. 12.

FIG. 14 is a sectional view taken along line 14-14 of FIG. 13.

FIG. 15 is like FIG. 14 and shows a further operational condition.

FIG. 16 is a schematic perspective view of another embodiment of a flowdirector for an inertial gas-liquid impactor separator in accordancewith the invention.

FIG. 17 is like FIG. 16 and shows a further operational condition.

FIG. 18 is like FIG. 16 and shows another embodiment.

FIG. 19 is like FIG. 18 and shows a further operational condition.

FIG. 20 is a schematic sectional view of another embodiment of a flowdirector for an inertial gas-liquid impactor separator in accordancewith the invention.

FIG. 21 is a schematic sectional view of another embodiment of a flowdirector for an inertial gas-liquid impactor separator in accordancewith the invention.

FIG. 22 is like FIG. 21 and shows another embodiment.

FIG. 23 is like FIG. 22 and shows another embodiment.

FIG. 24 is like FIG. 23 and shows another embodiment.

FIG. 25 is like FIG. 22 and shows another embodiment.

FIG. 26 is a schematic sectional view showing another embodiment of aflow director for an inertial gas-liquid impactor separator inaccordance with the invention.

FIG. 27 is a schematic perspective view of another embodiment of a flowdirector for an inertial gas-liquid impactor separator in accordancewith the invention.

FIG. 28 is like FIG. 27, showing a perspective cut-away view.

FIG. 29 is another perspective cut-away view of the component of FIG.28.

FIG. 30 is a perspective view of the component of FIG. 29.

FIG. 31 is a schematic sectional perspective view of another embodimentof a flow director for an inertial gas-liquid impactor separator inaccordance with the invention.

FIG. 32 is a schematic sectional view of another embodiment of a flowdirector for an inertial gas-liquid impactor separator in accordancewith invention.

FIG. 33 is like FIG. 32 and shows another embodiment.

FIG. 34 is a schematic sectional view of another embodiment of a flowdirector for an inertial gas-liquid impactor separator in accordancewith the invention.

DETAILED DESCRIPTION Prior Art

The following description of FIGS. 1-6 is taken from the above notedincorporated U.S. Pat. No. 6,290,738.

FIG. 1 shows an inertial gas-liquid separator 10 for removing andcoalescing liquid particles from a gas-liquid stream 12, and shown in anexemplary crankcase ventilation separation application for an internalcombustion engine 14. In such application, it is desired to ventcombustion blow-by gases from crankcase 16 of engine 14. Untreated,these gases contain particulate matter in the form of oil mist and soot.It is desirable to control the concentration of the contaminants,especially if the blow-by gases are to be recirculated back into theengine's air intake system, for example at air intake manifold 18. Theoil mist droplets are generally less than 5 microns in diameter, andhence are difficult to remove using conventional fibrous filter mediawhile at the same time maintaining low flow resistance as the mediacollects and becomes saturated with oil and contaminants.

Separator 10 includes a housing 20 having an inlet 22 for receivinggas-liquid stream 12 from engine crankcase 16, and an outlet 24 fordischarging a gas stream 26 to air intake manifold 18. Nozzle structure28 in the housing has a plurality of nozzles or holes 30 receiving thegas-liquid stream from inlet 22 and accelerating the gas-liquid streamthrough nozzles 30. An inertial collector 32 in the housing is in thepath of the accelerated gas-liquid stream and causes a sharp directionalchange thereof as shown at 36. Collector 32 has a rough porouscollection or impingement surface 34 causing liquid particle separationfrom the gas-liquid stream of smaller size liquid particles than asmooth non-porous impactor impingement surface and without the sharpcut-off size of the latter. The use of a rough porous collection surfaceis contrary to typical inertial gas-liquid separators, but isintentional in the present invention, for the above noted reasons, andas further noted herein.

The noted rough porous collection surface improves overall separationefficiency including for liquid particles smaller than the cut-off sizeof a smooth non-porous impactor impingement surface. The rough porouscollection surface causes both: a) liquid particle separation from thegas-liquid stream; and b) collection of the liquid particles within thecollection surface. The rough porous collection surface has a cut-offsize for particle separation which is not as sharp as that of a smoothnon-porous impactor impingement surface but improves collectionefficiency for particles smaller than the cut-off size as well as areduction in cut-off size. The rough porous collection surface providesa coalescing medium, such that liquid particles, once captured withinthe collection surface, will coalesce with other liquid particles in thecollection surface, and such that the accelerated gas stream andresultant high velocity of gas at and within the collection surfacecreates drag forces sufficient to cause captured liquid to migrate toouter edges of the collection surface and shed off of the collector.After the noted sharp directional change, outlet 24 receives the gasstream, as shown at 38, absent the separated liquid particles.Collection surface 34 and nozzles 30 are separated by a gap 40sufficient to avoid excessive restriction. Housing 20 has a flow paththerethrough including a first flow path portion 42 for the gas-liquidstream between inlet 22 and gap 40, and a second flow path portion 44for the gas stream between gap 40 and outlet 24. The flow path throughhousing 20 has a directional change in gap 40 at collection surface 34,and another directional change in the noted second flow path portion, asshown at 46.

A pass-through filter 48, FIG. 1, in the noted second flow path portionprovides a back-up safety filter trapping liquid particles re-entrainedin the gas stream after separation at inertial collector 32. Drain 50 inthe housing drains separated fluid from the collector. In FIG. 1, drain50 drains the separated fluid externally of housing 20 as shown at 52back to crankcase 16. Drain 50 is gravitationally below and on theopposite side of collector 32 from pass-through filter 48. In FIG. 1,gas stream 26 flows along a vertical axial direction. Filter 48 extendsalong a radial left-right horizontal span perpendicular to the notedaxial vertical direction. The noted radial horizontal span ofpass-through filter 48 extends across the entire housing and is parallelto collection surface 34. The gas stream flows radially at 36 along andparallel to collection surface 34 after separation and then turns 90° asshown at 46 and flows through pass-through filter 48 to outlet 24 asshown at 38.

FIG. 2 is similar to FIG. 1 and uses like reference numerals whereappropriate to facilitate understanding. In FIG. 2, drain 54 drainsseparated fluid back to inlet 22. A second pass-through filter 56 in thehousing is gravitationally below and on the opposite side of collector32 from pass-through filter 48 and filters separated liquid fromcollector 32. Drain 54 drains filtered fluid through pass-through filter56 to inlet 22.

Drain 54 in FIG. 2 is also a bypass port through which gas-liquid stream12 may flow to gap 40 without being accelerated through nozzles 30. Thegas-liquid stream from inlet 22 thus has a main flow path throughnozzles 30 and accelerated through gap 40 against collector 32, and analternate flow path through filter 56 and bypass port 54 to gap 40.Pass-through filter 56 in the noted alternate flow path traps andcoalesces liquid in the gas-liquid stream from inlet 22 to remove liquidfrom the gas stream supplied to outlet 24 through the noted alternateflow path. Outlet 24 thus receives a gas stream from the noted main flowpath with liquid removed by collector 32, and also receives a gas streamfrom the noted alternate flow path with liquid removed by pass-throughfilter 56. Inlet 22 is gravitationally below pass-through filter 56.Liquid removed by pass-through filter 56 from the gas-liquid stream inthe noted alternate flow path thus drains to inlet 22. Pass-throughfilter 56 also filters liquid removed from the gas-liquid stream in thenoted main flow path by collector 32 and drains such liquid throughdrain 54 and filter 56 back to inlet 22.

FIG. 3 uses like reference numerals from above where appropriate tofacilitate understanding. In FIG. 3, the axial flow of the gas streamthrough the housing is horizontal. Drain 58 in the housing drainsseparated fluid from the collector externally of the housing back tocrankcase 16. Drain 58 is in the noted second flow path portion 44 anddrains separated fluid from collector 32 through pass-through filter 48such that the latter filters both gas stream 26 and the separated fluid.Drain 58 is between pass-through filter 48 and outlet 24, and isgravitationally below collector 32 and outlet 24 and pass-through filter48.

FIG. 4 uses like reference numbers from above where appropriate tofacilitate understanding. FIG. 4 shows a vertical orientation of gasflow axially through a housing 60 having an inlet 62 for receivinggas-liquid stream 12, and an outlet 64 for discharging gas stream 26.Nozzle structure 66 in the housing has a plurality of nozzles or holes68 receiving the gas-liquid stream from inlet 62 and accelerating thegas-liquid stream radially horizontally through nozzles 68 and radiallythrough annular gap 70 to impinge annular inertial collector 72.Collector 72 is in the path of the accelerated gas-liquid stream andcauses a sharp directional change thereof and has a rough porouscollection surface 74, as above. The housing has a vertical axial flowpath therethrough including a first flow path portion 76 for thegas-liquid stream between inlet 62 and gap 70, and a second flow pathportion 78 for the gas stream between gap 70 and outlet 64. The flowpath has a directional change 80 in gap 70 at collection surface 74, anda directional change 82 in flow path portion 76. Each of directionalchanges 82 and 80 is 90°. Pass-through filter 84 in flow path portion 78in the housing provides a back-up safety filter trapping liquidparticles re-entrained in the gas stream after separation at inertialcollector 72. Filter 84 extends horizontally along a radial spanrelative to the noted vertical axial direction. The radial horizontalspan of filter 84 extends across the entire housing and is perpendicularto collection surface 74. After the noted directional change 80, the gasstream flows axially along and parallel to collection surface 74 andthen flows axially through pass-through filter 84 to outlet 64. Drain 86in housing 60 drains separated fluid from collector 72 externally of thehousing back to engine crankcase 16. Drain 86 is gravitationally belowand on the opposite side of collector 72 from pass-through filter 84.

FIG. 5 is similar to FIG. 4 and uses like reference numerals whereappropriate to facilitate understanding. In FIG. 5, drain 88 in thehousing drains separated fluid from collector 72 to inlet 62. Drain 88is gravitationally below and on the opposite side of collector 72 frompass-through filter 84. A second pass-through filter 90 in the housingis gravitationally below and on the opposite side of collector 72 frompass-through filter 84 and filters separated fluid from collector 72drained through drain 88 to inlet 62. The drain is provided by aplurality of holes or ports 88 in nozzle structure 66.

Ports 88 in FIG. 5 are also bypass ports through which gas-liquid stream12 may flow to gap 70 without being accelerated through nozzles 68. Thegas-liquid stream from inlet 62 thus has a main flow path throughnozzles 68 and accelerated through gap 70 against collector 72, and analternate flow path through bypass ports 88 and filter 90 to gap 70.Pass-through filter 90 in the noted alternate flow path traps andcoalesces liquid in the gas-liquid stream to remove liquid from the gasstream supplied to outlet 64. Outlet 64 thus receives a gas stream fromthe noted main flow path with liquid removed by collector 72, andreceives a gas stream from the noted alternate flow path with liquidremoved by pass-through filter 90. Inlet 62 is gravitationally belowpass-through filter 90. Liquid removed by pass-through filter 90 fromthe gas-liquid stream in the noted alternate flow path thus drainsthrough drain or bypass ports 88 to inlet 62. Pass-through filter 90also filters liquid removed from the gas-liquid stream in the noted mainflow path by collector 72 and drains such liquid back through drain 88to inlet 62.

FIG. 6 shows an inertial gas-liquid separator 92 for removing andcoalescing liquid particles from a gas-liquid stream 94. Housing 92 hasan inlet 96 for receiving gas-liquid stream 94, and an outlet 98 fordischarging a gas stream 100. Nozzle structure 102 in the housing has aplurality of nozzles 104 receiving the gas-liquid stream from inlet 96and accelerating the gas-liquid stream through the nozzles. An inertialcollector 106 in the housing in the path of the accelerated gas-liquidstream causes a sharp directional change thereof as shown at 108. Thecollector has a rough porous collection surface 110 causing liquidparticle separation from the gas-liquid stream. Drain 112 in the housingdrains separated fluid from the collector back to crankcase 16.

Nozzles 104 in FIG. 6 have an upstream entrance opening 114, and adownstream exit opening 116. Entrance opening 114 is larger than exitopening 116. The nozzles have a frusto-conical tapered transitionsection 118 between the entrance and exit openings. The frusto-conicaltapered transition section has an upstream end 120 of a first diameterat entrance opening 114, and has a downstream end 122 of a seconddiameter smaller than the noted first diameter. Downstream end 122 offrusto-conical tapered transition section 118 is spaced from exitopening 116 by a second transition section 124 of constant diameterequal to the noted second diameter.

In one embodiment, collection surface 34, FIGS. 1-3, 74, FIGS. 4 and 5,110, FIG. 6, is a fibrous collection surface comprising a plurality oflayers of fibers. At least two or three layers of fibers are desirableand provide improved performance. In the preferred embodiment, at leastone hundred layers of fibers are provided. The fibers have a diameter atleast three times the diameter of the liquid particles to be separatedand captured. In preferred form, the fiber diameter is in the range of50 to 500 microns. For oil mist droplets in the range from 0.3 micronsto 3 microns, with a 1.7 micron average, particle separation efficiencyimproved to 85% mass efficiency with the noted fibrous collectionsurface, as comparing to 50% mass efficiency for a smooth non-porouscollection surface.

In another embodiment, the collection surface is a porous collectionsurface of porosity between 50% and 99.9%. The average pore size is atleast five to ten times the diameter of the liquid particles, andpreferably at least 25 to 50 microns.

In another embodiment, the collection surface is a rough collectionsurface having a roughness measured in peak-to-valley height of at leastten times the diameter of the liquid particles. The peak to valleyheight is measured parallel to the direction of gas-liquid flow from thenozzles to the collection surface. The peak-to-valley height ispreferably at least 10 microns.

Present Application

The present application is directed to an inertial gas-liquid impactorseparator 10 for removing liquid particles from a gas-liquid stream 12,FIG. 1, 94, FIG. 6, as above, including a housing 20, 92 having an inlet22, 96 for receiving gas-liquid stream 12, 94, and an outlet 24, 98 fordischarging a gas stream 26, 100. A nozzle structure or plate 28, 102has at least one and preferably a plurality of nozzles or orifices orholes 30, FIG. 1, 104, FIG. 6, receiving the gas-liquid stream from theinlet and accelerating the gas-liquid stream through the nozzles. Aninertial gas impactor collector 32, FIG. 1, 110, 106, FIG. 6, in thehousing in the path of the accelerated gas-liquid stream causes liquidparticle separation, as noted above. In the present application, a flowdirector directs flow through the housing from the inlet to the outletalong a flow path from upstream to downstream. Various embodiments aredisclosed.

In FIGS. 7, 8, the flow director is provided by a flow controller in theform of a membrane 202 extending across the nozzles such as 104, FIG. 6,wherein the membrane deforms in response to increased flow. In oneembodiment, the membrane deforms by rupturing. For example, membrane 202may have a permanently open area at 204 providing continuous flowagainst inertial impactor collector 110, 106, FIG. 6, and may have amatrix 206 of a plurality of deformation sections such as 208, 210,etc., at respective nozzles 104. The deformation sections of themembrane are programmable or selectable to respond to different flowpressure, such that in response to increasing flow pressure, increasingnumbers of membrane sections deform or rupture to provide flow throughincreasing numbers of respective nozzles 104. In the embodiment shown inFIGS. 7 and 8, membrane sections 208 are open, and membrane sections 210remain closed, with the latter being programmed or selected to ruptureor open at higher flow pressures.

In various applications, including for separating oil from blowby gas ofan internal combustion engine, it is desired to provide increasedseparation efficiency early in the life of the engine without sufferingobjectionably high pressure drop late in the life of the engineincluding end-of-life condition of the engine. As an engine wears, moreblowby gas is created, and the impactor in the inertial gas-liquidseparator sees a larger flow and increased pressure from the crankcase.When this happens, the separator actually begins to perform with higherefficiency, but also has a larger pressure drop. Standard impactorseparators must be designed to meet this end-of-life condition in ordernot to produce too high of a pressure drop. This means that theefficiency early in the life of the engine may not be optimized.Multiple stages are known to allow the impactor design to be optimizedfor several points in the life of the engine. For example, in one knownembodiment, the blowby gas is exposed to fewer nozzles in the beginningwhen pressure and flow are lower. As pressure increases, more stages areopened. This means that efficiency can be high from the beginning oflife, and pressure drop is controlled as the engine wears. It is alsoknown to have one impactor stage that is constantly open to blowby gasflow, and one or more stages are that opened with relief valves aspressure increases. In one known embodiment, only the constant stageimpactor is open at the beginning-of-life of the engine, and all stageswill open by the end-of-life of the engine. It is also known to providean inertial gas-liquid impactor separator with variable orifice jetnozzle structure having a variable orifice area. The present membraneflow director and flow controller accommodates these desirableobjectives and is a further alternative to the described known subjectmatter. Rupture sections 208, 210 of matrix 206 respond to differentflow pressure, such that in response to increasing flow pressure,increasing numbers of rupture sections 208, 210, etc., rupture toprovide flow through increasing numbers of respective nozzles 30, FIG.1, 104, FIG. 6. In one form, membrane 202 is a thermoelastomericdiaphragm. Membrane 202 may be upstream or downstream of the nozzleplate, and preferably extends along and parallel to and contiguous tothe nozzle plate.

FIG. 9 shows a further embodiment with membrane 212 in housing orchimney 214 and upstream of one or more nozzles 216. Membrane 212 mayrupture and/or deform and/or expand and/or enlarge, e.g. rupture at itscenter 218, which ruptured opening permits flow to the group of one ormore nozzles 216. Portion 220 of the housing or chimney has no membranethereacross, and the group of one or more nozzles 222 continuallyreceives the gas-liquid stream. FIG. 10 shows a further embodiment withmembrane 224 downstream of a group of one or more nozzles 226 anddeformable or rupturable at a central section 228 to pass flowtherethrough from the group of nozzles 226. The group of nozzles 230have no membrane thereacross nor downstream thereof nor upstreamthereof, and continually pass the gas-liquid stream therethrough. FIG.11 shows a further embodiment with a membrane 232 immediately downstreamof a group of one or more nozzles 234, with the membrane havingindividual rupturable or deformable sections 236, one for each nozzle.The group of nozzles 238 have no membrane thereacross, or the membranealready has pre-formed openings 240 enabling continuous flow through thegroup of nozzles 238.

In FIGS. 12-15, the flow director is provided by a flow controller inthe form of a hinged plate 250, hinged at pivot or hinge 252, andextending across one or more nozzles 30, 104. In one embodiment, thehinged plate is provided by a cap having an aperture 254 therethroughproviding a tea kettle valve. Aperture or opening 254 provides apermanently open area through which the gas-liquid stream continuouslyflows against the inertial impactor collector 32, 110, 106. As notedabove, an internal combustion engine generates blowby gas as the notedgas-liquid stream, including increasing flow and pressure as the engineages and wears. Flow rate can also change as a result of a changingengine condition, e.g. load, torque, speed, etc. The tea kettle valveaperture 254 maintains a desired pressure drop during an early-in-lifecondition of the engine at low blowby gas flow, as shown at the closedcondition of the tea kettle valve in FIG. 14, wherein the gas-liquidstream flows only through opening or aperture 254, as shown at arrows256. The tea kettle valve cap 250 opens, FIG. 15, in response toincreasing blowby gas flow to maintain a designated pressure drop duringa late-in-life condition of the engine at higher blowby gas flow. InFIG. 15, additional gas-liquid flow is shown at arrows 258. Cap 250 ismovable to open and close nozzles 30, 104, FIGS. 14 and 15,respectively. The cap has the noted aperture 254 passing flowtherethrough, including when the cap is closed, FIG. 14, to maintain agiven pressure drop at a given low flow condition. The cap opens, FIG.15, in response to increased flow to maintain a designated pressure dropat a designated higher flow condition.

FIGS. 16-19 show a further embodiment with a flow director provided by aflow controller in the form of a reed valve 270 having a normally closedcondition, FIG. 16, and having an open condition, FIG. 17, in responseto increasing flow. In an alternative, a flapper valve 272 may be hingedas shown at 274, and have a closed condition, FIG. 18, and an opencondition, FIG. 19, in response to increased flow.

In the embodiments of FIGS. 20-25, the flow director is provided by aflow controller in the form of a variable actuator variably changing thedistance between the nozzle 30, 104 and the inertial impactor collector32, 110, 106. In FIG. 20, the variable actuator is provided byresiliently biasing, e.g. at spring 280, the inertial impactor collector110, 106 to change the distance between nozzle 104 and inertial impactorcollector 110, 106 in response to changing flow, e.g. increasing flowpushes harder against impaction media 110 and backing plate 106 toresiliently compress spring 280, thus increasing the distance 282between nozzle 104 and inertial impactor collector 110, 106. In responseto decreasing flow, spring 280 moves impactor collector 110, 106downwardly to decrease distance 282. In FIG. 21, an upstream valve maybe provided at 284 in housing or chimney 286 and biased downwardly to aclosed position by spring 288 against valve seat 290. In response toincreasing flow axially upwardly as shown at arrow 292, valve 284 movesupwardly off of valve seat 290, whereby the flow can then pass upwardlyinto plenum 294 and then to nozzle 104 to be accelerated thereby againstimpaction media 110. In FIG. 22, the housing or chimney 286 has a nozzleplate 296 which may be fixed or may be slidable to control the noteddistance 282 to impaction media 110. Impaction media 110 may be mountedto the underside of an impactor collector plate 298 which may be biaseddownwardly by a spring such as 280, or may be free-floating and biaseddownwardly only by gravity. In the orientations of FIGS. 20-22, thegas-liquid stream is accelerated by the nozzles 104 along an axialdirection 300 against inertial impactor collector 110. At least one ofthe nozzle and the inertial impactor collector is axially movable alongaxial direction 300 to change the axial distance 282 between the nozzleand the inertial impactor collector. In various embodiments as shown,one or both of the nozzle and the inertial impactor collector is movablealong axial direction 300. In FIG. 23, inertial impactor collector 302is mounted on a threaded shank 304 extending along an axis 306 along thenoted axial direction and rotates about axis 306 to change the notedaxial distance 282 between inertial impactor collector 302 and nozzle104. In FIG. 24, the nozzle is further provided by a plurality oftubular members 308, 310, etc. concentric about and telescopicallyextending along axis 306 and axially telescopically extensible andretractable to change the axial distance 282 between inertial impactorcollector 110 and the nozzle. In some embodiments, it may be desirableto provide the variable actuator as a resiliently biased nozzle, asshown at biasing spring 312 in FIG. 25.

In FIG. 26, the flow director is provided by a curved nozzle plate 320having a plurality of nozzles 104, and preferably a curved inertialimpactor collector plate 322. The gas-liquid stream flows axially alongaxial direction 324 to a plenum 326 about which curved nozzle plate 320forms an arc, whereafter the gas-liquid stream diverges in a fan-shapealong a plurality of nonparallel vectors 328, 330, 332, etc., againstcurved arcuate nozzle plate 320, with a given vector such as 328continuing axially along the noted axial direction, and with othervectors such as 330, 332 extending obliquely relative to axial direction324.

In FIGS. 27-30, the flow director is provided by a pair of combinednozzle/impactor plates 340 and 342 facing each other across a gap 344.First nozzle/impactor plate 340 has at least a first acceleration nozzle346 therethrough. Second nozzle/impactor plate 342 has at least a secondacceleration nozzle 348 therethrough. Preferably, a plurality of nozzlesare formed through each of plates 340 and 342. The noted firstacceleration nozzle 346 accelerates flow therethrough as shown at arrow350 and across gap 344 against second nozzle/impactor plate 342providing a first inertial impactor collector causing liquid particleseparation. The noted second acceleration nozzle 348 accelerates flowtherethrough as shown at arrow 352 and across gap 344 against firstnozzle/impactor plate 340 providing a second inertial impactor collectorcausing liquid particle separation. Flow across gap 344 from firstacceleration nozzle 346 to second nozzle/impactor plate 342 is along afirst direction, e.g. downwardly in FIGS. 27, 28, as shown at arrow 350.Flow across gap 344 from second acceleration nozzle 348 to firstnozzle/impactor plate 340 is along a second direction, e.g. upwardly inFIGS. 27, 28 as shown at arrow 352. The noted second direction 352 isopposite to the noted first direction 350. First nozzle/impactor plate340 provides both an acceleration nozzle and an inertial impactorcollector, namely: a) the acceleration nozzle 346 for flow along thenoted first direction 350; and b) the inertial impactor collector forflow along the noted second direction 352. Second nozzle/impactor plate342 provides both an acceleration nozzle and an inertial impactorcollector, namely: a) the acceleration nozzle 348 for flow along thenoted second direction 352; and b) the inertial impactor collector forflow along the noted first direction 350. First nozzle/impactor plate340 has an upstream surface 354 and a distally oppositely facingdownstream surface 356. Second nozzle/impactor plate 342 has an upstreamsurface 358 and a distally oppositely facing downstream surface 360.Downstream surfaces 356 and 360 of the first and second nozzle/impactorplates 340 and 342, respectively, face each other across gap 344. Thegas-liquid stream 94 flows axially along axial direction 362 to apre-separation plenum 364 in housing 366, and flows to upstream surface354 of first nozzle/impactor plate 340 and to upstream surface 358 ofsecond nozzle/impactor plate 342 and then transversely in oppositedirections 350 and 352 through respective first and second accelerationnozzles 346 and 348 and into gap 344. The flow exits gap 344 along axialdirection 362 through outlet 368 after liquid particle separation atfacing downstream surfaces 356 and 360 of first and secondnozzle/impactor plates 340 and 342, respectively, providing the notedfirst and second inertial impactor collectors, respectively. First andsecond nozzle plates 340 and 342 have respective first and secondnozzles 346 and 348 therethrough, with first nozzle plate 340 being aninertial impactor collector for second nozzle 348, and with secondnozzle plate 342 being an inertial impactor collector for first nozzle346.

In FIG. 31, the separator is provided for an internal combustion enginehaving a valve cover 380. An outer cover 382 is provided over at least aportion of and is spaced outwardly of valve cover 380. Outer cover 382has an inner surface 384 spaced from valve cover 380 by a gap 386through which the gas-liquid stream is accelerated by nozzle 104 whichis provided through valve cover 380. Inner surface 384 of outer cover382 provides an inertial impactor collector and causes liquid particleseparation. In one embodiment, at least one of the inner surface 384 ofouter cover 382 and valve cover 380 at nozzle 104 is convexly curvedtoward the other of inner surface 384 of outer cover 382 and valve cover380 at nozzle 104. This enables selection of the distance across the gapor spacing at 386. This also can accommodate an adjacent external partof irregular shape, e.g. at 388.

In FIGS. 32, 33, the flow director is provided by a resiliently biasedplunger or valve, e.g. 390, having a valve face 392 engageable with avalve seat 394 having a self-seating tolerance-accommodatingconfiguration. Housing 396 has a primary always-open flow passage 398supplying flow to nozzles at 104, and has a secondary flow passage 400controlled by plunger or valve 390 supplying flow to nozzles at 104 a.In the preferred embodiment, valve face 392 and valve seat 394 engagealong a tapered surface, e.g. the outer arcuate surface of a ballprovided by ball plunger 390. In another embodiment, the plunger isprovided by a bowl 402, FIG. 33, which may be biased downwardly bygravity as in FIG. 32, or may be additionally biased by a spring such as404. Plungers 390, 402 provide a relief valve enabling increased flow atincreasing pressure.

In FIG. 34, first and second flow paths 410 and 412 are provided inhousing 414. First flow path 410 has a first set of one or more nozzles416 receiving the gas-liquid stream 94 from inlet 96, which may becontrolled by an inlet valve 418 biased by spring 420. The gas-liquidstream in first flow path 410 is accelerated through the first set ofone or more nozzles 416. Second flow path 412 has a second set of one ormore nozzles 422 receiving the gas-liquid stream from first flow path410 and accelerating the gas-liquid stream through the second set of oneor more nozzles 422 and against inertial impactor collector 424. Firstand second flow paths 410 and 412 are in series. Second flow path 412may include an entrance valve 426 biased by spring 428. A third flowpath 430 is provided in the housing and has a third set of one or morenozzles 432 accelerating the gas-liquid stream therethrough, with thethird flow path being in parallel with at least one of the first andsecond flow paths. In one embodiment, flow paths A, B, C and D in thehousing provide cumulatively increasing flow, wherein flow path A isalways open and provides inertial impaction separation at an inertialimpactor collector E, and having an actuator F opening flow path B toflow to flow path C in response to increasing pressure, wherein flowpath C provides inertial impaction separation at an inertial impactorcollector G, and having an actuator H opening flow path D to flow fromflow path B, wherein flow path D provides inertial impaction separationat inertial impactor collector G. Flow paths C and D have upstream endsmeeting at a common junction 431 at a downstream end of flow path B, andwherein flow from flow path B splits at common junction 431 into a firstflow branch 433 flowing to flow path C, and a second flow branch 435flowing to flow path D. One or more acceleration nozzles 416 at commonjunction 431 accelerates flow from flow path B to flow paths C and D atthe noted first and second flow branches, respectively. In a furtherembodiment, third flow path 430 is in parallel with first flow path 410,and the third set of one or more nozzles 432 accelerates the gas-liquidstream therethrough against a second inertial impactor collector 434causing liquid particle separation. In a further embodiment, a fourthflow path may be provided at 436 and have a fourth set of one or morenozzles 438 accelerating the gas-liquid stream therethrough, with thefourth flow path in parallel with the noted second flow path, and thenoted fourth set of one or more nozzles accelerating the gas-liquidstream therethrough against inertial impactor collector 424. A yetfurther flow path may be provided at 440 and having a further set of oneor more nozzles 442 accelerating the gas-liquid stream therethroughagainst inertial impactor collector 424. The various flow paths provideflow director structure therethrough guiding flow to the next flow pathand/or to a respective inertial impactor collector, etc.

In the foregoing description, certain terms have been used for brevity,clearness, and understanding. No unnecessary limitations are to beinferred therefrom beyond the requirement of the prior art because suchterms are used for descriptive purposes and are intended to be broadlyconstrued. The different configurations, systems, and method stepsdescribed herein may be used alone or in combination with otherconfigurations, systems and method steps. It is to be expected thatvarious equivalents, alternatives and modifications are possible withinthe scope of the appended claims.

What is claimed is:
 1. An inertial gas-liquid impactor separator forremoving liquid particles from a gas-liquid stream comprising a housinghaving an inlet for receiving a gas-liquid stream and an outlet fordischarging a gas stream, at least one nozzle in said housing receivingsaid gas-liquid stream from said inlet and accelerating said gas-liquidstream through said nozzle, an inertial impactor collector in saidhousing in the path of said accelerated gas-liquid stream and causingliquid particle separation, and a flow director directing flow throughsaid housing from said inlet to said outlet along a flow path fromupstream to downstream, the flow director comprising a pair of combinednozzle/impactor plates facing each other across a gap, comprising afirst nozzle/impactor plate having at least a first acceleration nozzletherethrough, and a second nozzle/impactor plate having at least asecond acceleration nozzle therethrough, said first acceleration nozzleaccelerating flow therethrough and across said gap against said secondnozzle/impactor plate providing a first inertial impactor collectorcausing liquid particle separation, said second acceleration nozzleaccelerating flow therethrough and across said gap against said firstnozzle/impactor plate providing a second inertial impactor collectorcausing liquid particle separation.
 2. The inertial gas-liquid impactorseparator according to claim 1, wherein flow across said gap from saidfirst acceleration nozzle to said second nozzle/impactor plate is alonga first direction, and flow across said gap from said secondacceleration nozzle to said first nozzle/impactor plate is along asecond direction, wherein said second direction is opposite to saidfirst direction.
 3. The inertial gas-liquid impactor separator accordingto claim 2, wherein: said first nozzle/impactor plate provides both anacceleration nozzle and an inertial impactor collector, namely: a. theacceleration nozzle for flow along said first direction; and b. theinertial impactor collector for flow along said second direction; saidsecond nozzle/impactor plate provides both an acceleration nozzle and aninertial impactor collector, namely: a. the acceleration nozzle for flowalong said second direction; and b. the inertial impactor collector forflow along said first direction.
 4. The inertial gas-liquid impactorseparator according to claim 3, wherein said first nozzle/impactor platehas an upstream surface and a distally oppositely facing downstreamsurface, said second nozzle/impactor plate has an upstream surface and adistally oppositely facing downstream surface, wherein said downstreamsurfaces of said first and second nozzle/impactor plates face each otheracross said gap.
 5. The inertial gas-liquid impactor separator accordingto claim 4, wherein said gas-liquid stream flows axially along an axialdirection to a pre-separation plenum, and flows to said upstream surfaceof said first nozzle/impactor plate and to said upstream surface of saidsecond nozzle/impactor plate and then transversely in oppositedirections through respective said first and second acceleration nozzlesand into said gap.
 6. The inertial gas-liquid impactor separatoraccording to claim 5, wherein flow exits said gap along said axialdirection after said liquid particle separation at said facingdownstream surfaces of said first and second nozzle/impactor platesproviding said second and first inertial impactor collectors,respectively.
 7. The inertial gas-liquid impactor separator according toclaim 1, wherein the first nozzle/impactor plate comprises a firstplurality of acceleration nozzles therethrough, the first plurality ofacceleration nozzles including the first acceleration nozzle.
 8. Theinertial gas-liquid impactor separator according to claim 7, wherein thesecond nozzle/impactor plate comprises a second plurality ofacceleration nozzles therethrough, the second plurality of accelerationnozzles including the second acceleration nozzle.
 9. The inertialgas-liquid impactor separator according to claim 7, wherein the secondacceleration nozzle is not axially aligned with any of the firstplurality of acceleration nozzles.
 10. The inertial gas-liquid impactorseparator according to claim 1, wherein flow across the gap from thefirst acceleration nozzle to the second nozzle/impactor plate is along afirst direction, and wherein flow across the gap from the secondacceleration nozzle to the first nozzle/impactor plate is along a seconddirection opposite the first direction.
 11. The inertial gas-liquidimpactor separator according to claim 1, wherein the housing comprises apre-separation plenum, and wherein the gas-liquid stream flows axiallyalong an axial direction to the pre-separation plenum before flowing toan upstream surface of first nozzle/impactor plate and an upstreamsurface of the second nozzle/impactor plate.
 12. The inertial gas-liquidimpactor separator according to claim 11, wherein, after liquid particleseparation at a downstream surface of the first nozzle/impactor plateand a downstream surface of the second nozzle/impactor plates, aseparated gas stream exits the housing through an outlet along the axialdirection.
 13. The inertial gas-liquid impactor separator according toclaim 11, wherein flow of the gas-liquid stream to the plenum is in adirection that is substantially orthogonal to flow of the gas-liquidstream through the first acceleration nozzle and the second accelerationnozzle.
 14. The inertial gas-liquid impactor separator according toclaim 1, wherein the first acceleration nozzle of the firstnozzle/impactor plate is not axially aligned with the secondacceleration nozzle of the second nozzle/impactor plate.
 15. Theinertial gas-liquid impactor separator according to claim 1, wherein thefirst nozzle/impactor plate and the second nozzle/impactor plate areintegrally formed as a single component.